Changes in surface topography at the TKA backside articulation following in vivo service: a retrieval analysis

Retrieval analysis in total knee arthroplasty

Retrieval analysis in total knee arthroplasty (TKA) has been little studied in the literature. A narrative review of the literature to understand the current importance of retrieval analysis in TKA has been conducted. On August 27, 2024, a literature search was performed in PubMed using "TKA retrieval analysis" as keywords. A total of 160 articles were found, of which only 19 were analyzed because they were directly related to the subject of this article. Rotating-platform (mobile-bearing) TKA has no surface damage advantage over fixed-bearing TKA. TKAs with central locking mechanisms are more prone to debond from the cement mantle. No major wear of the polyethylene (PE) component in TKA using oxidized zirconium components occurs. Femoral components of cobalt-chromium roughen more than oxidized zirconium femoral components. The use of a polished tibial tray over an unpolished design is advised. At short-run assessment (15 months on average), antioxidant-stabilized highly crosslinked PE components are not clinically different in surface damage, density of crosslinking, or oxidation compared to standard remelted highly crosslinked PE components. A correlation between implant position and PE component surface damage has been reported. It shows the importance of optimizing component position to reduce PE component damage. Contemporary knee tumor megaendoprostheses show notable volumetric metal wear originated at the rotating hinge. Retrieval analysis in TKA renders relevant data on how different prosthetic designs described in the literature perform. Such information can help to improve future prosthetic designs to increase prosthetic survival.

Development of a bespoke finite element wear algorithm to investigate the effect of femoral centre of rotation on the wear evolution in total knee replacements

Total Knee Replacements (TKRs) are a commonly used treatment to help patients suffering from severely damaged knee joints, which is normally brought on by osteoarthritis. The aim of the surgery is to reduce pain and regain function of the joint, however, some of these implants fail prematurely with implant wear being one of the main factors of failure. Computational analysis is an efficient tool that can provide an in-depth insight on the evolution of wear, before utilising experimental techniques which are time-consuming and costly. In this study, a bespoke finite element (FE) based wear algorithm has been further developed for TKRs and was used to investigate how location of femoral centre of rotation (CoR) affects the evolution of wear at the bearing surfaces. Three locations of femoral CoR have been investigated: international standards (ISO) CoR, being the location defined in ISO 14243-3, distal CoR being the centre of the femoral component's distal radius, and reference CoR being the middle ground between the two. All investigations were setup in accordance with ISO 14243-3 for displacement-controlled wear testing conditions for knee simulators. The wear algorithm extracts contact pressure and sliding distance from the FE analysis to determine wear depth, wear pattern, volumetric wear, and wear rates on the polymeric insert and femoral component's bearing surfaces using Archard's wear law. The polymeric insert volumetric wear rate after 5 million cycles (Mc) for ISO, reference, and distal CoR are 4.37mm3/Mc, 5.40mm3/Mc, and 6.83mm3/Mc respectively. Furthermore, the wear pattern's location on the bearing surfaces is dependent on the femoral CoR, with ISO CoR wear pattern being positioned more posteriorly, distal CoR being more anteriorly, and reference CoR in between ISO and distal. The ISO CoR investigation showed a region of minimal wear between two wear regions at the middle of the femoral component's wear pattern, on both medial and lateral condyles. This region of minimal wear reduces for the reference CoR and further reduces for the distal CoR. After 5 Mc, the average polymeric insert-femoral component contact area changes with femoral CoR, with the average contact area being 66.53mm2, 68.35mm2, and 71.21mm2 for ISO, reference, and distal CoRs respectively, with distal having around 7% more contact area than ISO. The results from this study show that there is a wide range of wear values for different locations of femoral CoR. As such the choice of femoral CoR should be carefully considered when performing any wear investigation to ensure that the CoR location is consistent for all studies being compared.

Linear and Volumetric Polyethylene Wear Patterns after Primary Cruciate-Retaining Total Knee Arthroplasty Failure: An Analysis Using Optical Scanning and Computer-Aided Design Models

(1) Background: Analyses of retrieved inserts allow for a better understanding of TKA failure mechanisms and the detection of factors that cause increased wear. The purpose of this implant retrieval study was to identify whether insert volumetric wear significantly differs among groups of common causes of total knee arthroplasty failure, whether there is a characteristic wear distribution pattern for a common cause of failure, and whether nominal insert size and component size ratio (femur-to-insert) influence linear and volumetric wear rates. (2) Methods: We digitally reconstructed 59 retrieved single-model cruciate-retaining inserts and computed their articular load-bearing surface wear utilizing an optical scanner and computer-aided design models as references. After comprehensively reviewing all cases, each was categorized into one or more of the following groups: prosthetic joint infection, osteolysis, clinical loosening of the component, joint malalignment or component malposition, instability, and other isolated causes. The associations between volumetric wear and causes of failure were estimated using a multiple linear regression model adjusted for time in situ. Insert linear penetration wear maps from the respective groups of failure were further processed and merged to create a single average binary image, highlighting a potential wear distribution pattern. The differences in wear rates according to nominal insert size (small vs. medium vs. large) and component size ratio (≤1 vs. >1) were tested using the Kruskal-Wallis test and the Mann-Whitney test, respectively. (3) Results: Patients with identified osteolysis alone and those also with clinical loosening of the component had significantly higher volumetric wear when compared to those without both causes (p = 0.016 and p = 0.009, respectively). All other causes were not significantly associated with volumetric wear. The instability group differentiated from the others with a combined peripheral antero-posterior wear distribution. Linear and volumetric wear rates showed no significant differences when compared by nominal insert size (small vs. medium vs. large, p = 0.563 and p = 0.747, respectively) or by component (femoral-to-insert) size ratio (≤1 vs. >1, p = 0.885 and p = 0.055, respectively). (4) Conclusions: The study found increased volumetric wear in cases of osteolysis alone, with greater wear when combined with clinical loosening compared to other groups. The instability group demonstrated a characteristic peripheral anterior and posterior wear pattern. Insert size and component size ratio seem not to influence wear rates.

Surface texture analysis of different focal knee resurfacing implants after 6 and 12 months in vivo in a goat model

The clinical success of osteochondral implants depends significantly on their surface properties. In vivo, an implant may roughen over time which can decrease its performance. The present study investigates whether changes in the surface texture of metal and two types of polycarbonate urethane (PCU) focal knee resurfacing implants (FKRIs) occurred after 6 and 12 months of in vivo articulation with native goat cartilage. PCU implants which differed in stem stiffness were compared to investigate whether the stem fixating the implant in the bone influences surface topography. Using optical profilometry, 19 surface texture parameters were evaluated, including spatial distribution and functional parameters obtained from the material ratio curve. For metal implants, wear during in vivo articulation occurred mainly via material removal, as shown by the significant decrease of the core-valley transition from 91.5% in unused implants to 90% and 89.6% after 6 and 12 months, respectively. Conversely, for PCU implants, the wear mechanism consisted in either filling of the valleys or flattening of the surface by dulling of sharp peaks. This was illustrated in the change in roughness skewness from negative to positive values over 12 months of in vivo articulation. Implants with a softer stem experienced the most deformation, shown by the largest change in material ratio curve parameters. We therefore showed, using a detailed surface profilometry analysis, that the surface texture of metal and two different PCU FKRIs changes in a different way after articulation against cartilage, revealing distinct wear mechanisms of different implant materials.

Comparative retrieval analysis of contemporary mobile and fixed unicompartmental knee bearing designs

There are two different concepts behind Unicompartmental Knee Replacement (UKR). Mobile bearings, as exemplified by the Oxford UKR, and fixed bearings, as exemplified by the Physica ZUK. These are the two most commonly implanted UKRs in the UK. For the first time, a comparison of the tribological features of 19 explanted Oxford and 19 explanted Physica ZUK UKRs was undertaken. Surface damage on the polyethylene (PE) inserts of the Oxford and Physica ZUK cohorts were assessed using an established semi-quantitative scoring method. The femoral components of both cohorts were assessed using a non-contact 3D profilometer to measure roughness values. It was found that the PE inserts of the Oxford cohort (22.54 ± 9.14) had statistically significant greater damage scores than the Physica ZUK cohort (16.50 ± 5.17) (p = 0.04). However, the femoral components of the Oxford cohort showed lower roughness values than the Physica ZUK cohort (p = 0.00). This is the first study that reports a comparative roughness analysis between retrieved Oxford and Physica ZUK UKR designs.

Less polyethylene wear in monobloc compared to modular ultra-high-molecular-weight-polyethylene inlays in hybrid total knee arthroplasty: A 5-year randomized radiostereometry study

BACKGROUND

A modular polyethylene (PE) inlay in total knee arthroplasty (TKA) may wear on both sides. PE particles may induce osteolysis, which can lead to implant loosening. The aim of this study was to determine if PE wear in monobloc TKA differs from that ofmodular TKA at 60-month follow-up.

PATIENTS AND METHODS

In a prospective, patient-blinded trial, 50 patients were randomized to hybrid TKA surgery with either acementless high-porosity trabecular-metal tibial component with a monobloc UHMWPE inlay (MONO-TM) or a cementless low-porosity screw-augmented titanium fiber-mesh tibial component with a modular UHMWPE inlay (MODULAR-FM). Radiostereometry was used to measure PE wear and tibial component migration.

RESULTS

At 60-monthfollow-up, mean PE wear of the medial compartment was 0.24 mm and 0.61 mm and mean PE wear of the lateral compartment was 0.31 mm and 0.82 mm for the MONO-TM and the MODULAR-FM groups, respectively (p < 0.01). The PE wear-rate was 0.05 mm (95% CI 0.03-0.08) in the MONO-TM group and 0.14 mm (95% CI 0.12-0.17) in the MODULAR-FM group (p < 0.01). Total translation at 60 months was mean 0.30 mm (95% CI 0.10-0.51) less (p < 0.01) for MONO-TM compared with MODULAR-FM tibial components. The majority of tibial components were stable (<0.2 mm MTPM) from 12 to 24-month and 24 to 60-month follow-up.

CONCLUSION

At mid-term follow-up, monobloc PE inlay wear was approximately 40% of that of the modular PE inlay wear, which suggest that back-side wear of modular PE inlays is a significant contributor of PE wear in hybrid TKA.

Retrieval analysis of an explanted Mobi-C cervical disc replacement: A case study

Ex vivo analysis of artificial discs is essential to better understand their ability to replace degenerated intervertebral discs. The Mobi-C differs from some other contemporary disc designs in that it has a mobile polyethylene insert that is sandwiched between superior and inferior cobalt chromium endplates. While some studies claim the Mobi-C to have restored normal cervical spinal biomechanics, others have noted high levels of migration. Our objective was to contribute to this debate by, for the first time, analysing an explanted Mobi-C cervical disc which was removed due to worsening myelopathy at the nano and macro scales. Intraoperatively, the insert was found to have excessively migrated and it compressed the spinal cord. Roughness was measured as 0.016 ± 0.006 μm (Sa) and 0.055 ± 0.020 μm (Sa) for the superior and inferior plates, and 1.210 ± 0.154 μm (Sa) and 0.446 ± 0.083 μm (Sa) for the superior and inferior surfaces of the insert. Compared to unworn surfaces, the roughness increased for the superior and inferior plates and decreased for both surfaces of the insert. However, the only statistically significant change occurred on the articulating surface of the inferior plate (p = 0.04). At the nanoscale, valleys dominated the articulating surfaces. The superior plate had a burnished appearance whereas the inferior plate appeared matt. Impingement was observed on the endplates. The insert was severely damaged, burnished and had scratches. Additionally, subsurface whitening and internal cracking were observed on the insert.

Explant analysis of a Maestro™ wrist prosthesis and calculation of its lubrication regime

Explant analysis can provide key insights to understanding failures of artificial joints and thus how they might be improved for the ultimate benefit of patients. There are no previous reports of explant analysis of an artificial wrist joint. In this study, an explanted metal-on-polymer Maestro wrist was analysed both in macro and nanoscales to estimate its biotribological performance. The articulation was formed between a cobalt chromium carpal head and an ultrahigh molecular weight polyethylene bearing. The surface roughness values of its articulating surfaces and the backside of the articulation were measured. On average, the articulating surface roughness values were calculated as 0.06 ± 0.02 μm and 1.29 ± 0.63 μm for the cobalt chromium carpal head and ultrahigh molecular weight polyethylene bearing, respectively. Both surfaces had negative skewness, indicating a preponderance of valleys. On the articulating surface of the carpal head, light scratches were observed, and no impingement was observed throughout the component. The polymeric surface had a polished appearance. It had unidirectional scratches at the centre of the articulation, pits of different sizes on its articulating surface, and matt white subsurface regions. The backside of the UHMWPE bearing and the convex surface of the radial body that it was sitting on, were found to have average surface roughness values of 4.23 ± 0.69 μm and 5.57 ± 1.05 μm, respectively. The difference in the means was not significant (p > 0.05). Taking the articulating surface roughness values, the lubrication regime that the explanted Maestro wrist operated under in vivo was estimated for varying physiological conditions, i.e. varying loads, entraining velocities and lubricant viscosities. In every case considered, the explant was found to operate under boundary lubrication.

Biomechanical Characteristics of Three Baseplate Rotational Arrangement Techniques in Total Knee Arthroplasty

Introduction

Several ongoing studies aim to improve the survival rate following total knee arthroplasty (TKA), which is an effective orthopedic surgical approach for patients with severely painful knee joint diseases. Among the studied strategies, baseplate rotational arrangement techniques for TKA components have been suggested but have been the subject of only simple reliability evaluations. Therefore, this study sought to evaluate comparatively three different baseplate rotational arrangement techniques that are commonly used in a clinical context.

Materials and Methods

Three-dimensional (3D) finite element (FE) models of the proximal tibia with TKA were developed and analyzed considering three baseplate rotational arrangement techniques (anterior cortex line, tibial tuberosity one-third line, and tibial tuberosity end line) for six activities of daily life (ADLs) among patients undergoing TKA. Mechanical tests based on the ASTM F1800 standard to validate the FE models were then performed using a universal testing machine. To evaluate differences in biomechanical characteristics according to baseplate rotational arrangement technique, the strain and peak von Mises stresses (PVMSs) were assessed.

Results

The accuracy of the FE models used in this study was high (94.7 ± 5.6%). For the tibial tuberosity one-third line rotational arrangement technique, strains ≤ 50 µstrain (the critical bone damage strain, which may affect bone remodeling) accounted for approximately 2.2%-11.3% and PVMSs within the bone cement ranged from 19.4 to 29.2 MPa, in ADLs with high loading conditions. For the tibial tuberosity end line rotational arrangement, strains ≤ 50 µstrain accounted for approximately 2.3%-13.3% and PVMSs within the bone cement ranged from 13.5 to 26.7 MPa. For anterior cortex line rotational arrangement techniques, strains ≤50 µstrain accounted for approximately 10.6%-16.6% and PVMSs within the bone cement ranged from 11.6 to 21.7 MPa.

Conclusion

The results show that the most recently developed frontal cortex line rotational alignment technique is the same or better than the other two rotational alignment techniques in terms of biomechanics. This finding can be, however, dependent on the contact characteristics between the baseplate and the proximal tibia. That is, it is indicated that the optimum baseplate rotational arrangement technique in terms of reducing the incidence of TKA mechanical failure can be achieved by adjusting the characteristics of contact between the baseplate and the proximal tibia.

High wear resistance of femoral components coated with titanium nitride: a retrieval analysis

PURPOSE

The objective of this study was to evaluate the in vivo wear resistance of cobalt-chromium femoral components coated with titanium nitride (TiN). Our null hypothesis was that the surface damage and the thickness of the TiN coating do not correlate with the time in vivo.

METHODS

Twenty-five TiN-coated bicondylar femoral retrievals with a mean implantation period of 30.7 ± 11.7 months were subjected to an objective surface damage analysis with a semi-quantitative assessment method. A visual examination of scratches, indentations, notches and coating breakthroughs of the surfaces was performed. The roughness and the coating thickness of the TiN coating were evaluated in the main articulation regions.

RESULTS

Narrow scratches and indentations in the range of low flexion angles on the retrieval surfaces were the most common modes of damage. There was no evidence of delamination on the articulation surface but rather at the bottom of isolated severe indentations or notches. An analysis of three retrievals revealed a coating breakthrough in the patellofemoral joint region, resulting from patella maltracking and a dislocation. The arithmetical mean roughness of the TiN surface slightly increased with the implantation period. In contrast, the maximum peak height of the roughness profile was reduced at the condyles of the retrieved components in comparison with new, unused surfaces. No significant association between the coating thickness and implantation period was determined. Moreover, the measured values were retained in the range of the initial coating thickness even after several years of in vivo service.

CONCLUSIONS

As was demonstrated by the results of this study, the surface damage to the TiN coating did not deteriorate with the implantation period. The calculated damage scores and the measured coating thickness in particular both confirmed that the TiN coating provides low wear rates. Our findings support the use of wear-resistant TiN-coated components in total knee arthroplasty with the objective of reducing the risk of aseptic loosening. However, in terms of TiN-coated femoral components, particular attention should be paid to a correct patellar tracking in order to avoid wear propagation at the implant.

A comparative surface topographical analysis of explanted total knee replacement prostheses: Oxidised zirconium vs cobalt chromium femoral components

It has been proposed that an increased surface roughness of the femoral components of Total Knee Replacements (TKRs) may be a contributing factor to the accelerated wear of the polyethylene (PE) bearing and ultimately prosthesis failure. Oxidised Zirconium was introduced to the orthopaedic market in an attempt to reduce PE wear associated failures and increase the longevity of the prosthesis. In this study, non-contacting profilometry was used to measure the surface roughness of the femoral components of 6 retrieved TKRs (3 Oxidised Zirconium (OxZr) and 3 Cobalt Chromium alloy (CoCr) femoral components) and 2 as-manufactured femoral components (1 OxZr and 1 CoCr). A semi-quantitative method was used to analyse the damage on the retrieved PE components. The S_a values for the retrieved OxZr femoral components (S_a = 0.093 µm ± 0.014) and for the retrieved CoCr femoral components (S_a = 0.065 µm ± 0.005) were significantly greater (p < .05) than the roughness values for the as-manufactured femoral components (OxZr S_a = 0.061 µm ± 0.004 and CoCr S_a = 0.042 µm ± 0.003). No significant difference was seen between the surface roughness parameters of the retrieved OxZr and retrieved CoCr femoral components. There was no difference between the PE component damage scores for the retrieved OxZr TKRs compared to the retrieved CoCr TKRs. These results agree with other studies that both OxZr and CoCr femoral components roughen during time in vivo but the lack of difference between the surface roughness measurements of the two materials is in contrast to previous topographical reports. Further analysis of retrieved OxZr TKRs is recommended so that a fuller appreciation of their benefits and limitations be obtained.

Peripheral snap-fit locking mechanisms and smooth surface finish of tibial trays reduce backside wear in fixed-bearing total knee arthroplasty

Background and purpose - Severe backside wear, observed in older generations of total knee replacements (TKRs), led to redesign of locking mechanisms to reduce micromotions between tibial tray and inlay. Since little is known about whether this effectively reduces backside wear in modern designs, we examined backside damage in retrievals of various contemporary fixed-bearing TKRs. Patients and methods - A consecutive series of 102 inlays with a peripheral (Stryker Triathlon, Stryker Scorpio, DePuy PFC Sigma, Aesculap Search Evolution) or dovetail locking mechanism (Zimmer NexGen, Smith and Nephew Genesis II) was examined. Articular and backside surface damage was evaluated using the semiquantitative Hood scale. Inlays were examined using scanning electron microscopy (SEM) to determine backside wear mechanisms. Results - Mean Hood scores for articular (A) and backside (B) surfaces were similar in most implants-Triathlon (A: 46, B: 22), Genesis II (A: 55, B: 24), Scorpio (A: 57, B: 24), PFC (A: 52, B: 20); Search (A: 56, B: 24)-except the NexGen knee (A: 57, B: 60), which had statistically significantly higher backside wear scores. SEM studies showed backside damage caused by abrasion related to micromotion in designs with dovetail locking mechanisms, especially in the unpolished NexGen trays. In implants with peripheral liner locking mechanism, there were no signs of micromotion or abrasion. Instead, "tray transfer" of polyethylene and flattening of machining was observed. Interpretation - Although this retrieval study may not represent well-functioning TKRs, we found that a smooth surface finish and a peripheral locking mechanism reduce backside wear in vivo, but further studies are required to determine whether this actually leads to reduced osteolysis and lower failure rates.

Monoblock versus modular polyethylene insert in uncemented total knee arthroplasty

Background and purpose - Backside wear of the polyethylene insert in total knee arthroplasty (TKA) can produce clinically significant levels of polyethylene debris, which can lead to loosening of the tibial component. Loosening due to polyethylene debris could theoretically be reduced in tibial components of monoblock polyethylene design, as there is no backside wear. We investigated the effect of 2 different tibial component designs, monoblock and modular polyethylene, on migration of the tibial component in uncemented TKA. Patients and methods - In this randomized study, 53 patients (mean age 61 years), 32 in the monoblock group and 33 in the modular group, were followed for 2 years. Radiostereometric analysis (RSA) was done postoperatively after weight bearing and after 3, 6, 12, and 24 months. The primary endpoint of the study was comparison of the tibial component migration (expressed as maximum total point motion (MTPM)) of the 2 different implant designs. Results - We did not find any statistically significant difference in MTPM between the groups at 3 months (p = 0.2) or at 6 months (p = 0.1), but at 12 and 24 months of follow-up there was a significant difference in MTPM of 0.36 mm (p = 0.02) and 0.42 mm (p = 0.02) between groups, with the highest amount of migration (1.0 mm) in the modular group. The difference in continuous migration (MTPM from 12 and 24 months) between the groups was 0.096 mm (p = 0.5), and when comparing MTPM from 3-24 months, the difference between the groups was 0.23 mm (p = 0.07). Interpretation - In both study groups, we found the early migration pattern expected, with a relatively high initial amount of migration from operation to 3 months of follow-up, followed by stabilization of the implant with little migration thereafter. However, the modular implants had a statistically significantly higher degree of migration compared to the monoblock. We believe that the greater stiffness of the modular implants was the main reason for the difference in migration, but an initial creep in the polyethylene metal-back locking mechanism of the modular group could also be a possible explanation for the observed difference in migration between the 2 study groups.